Method and apparatus for packaging wire in a wire container

Abstract

Large diameter weld wire and methods for forming a large diameter weld wire are provided, in which weld wire is formed and a sinusoidal shape memory is imparted on the wire to enhance feedability and ease of withdrawal from a storage spool or container.

1 . A method of forming a large diameter weld wire for storage on a spool or in a container, said method comprising: 
 forming a weld wire having a diameter of about 0.079 inches or more and about 0.190 inches or less; and    imparting a desired shape memory on said weld wire, said shape memory substantially lying in a single plane wherein said shape memory is generally a repeating waveform having a wavelength and a height for each waveform cycle.    
     
     
         2 . A method as defined in  claim 1 , wherein imparting said desired shape memory on said wire comprises imparting a sinusoidal waveform on said weld wire.  
     
     
         3 . A method as defined in  claim 1 , wherein said waveform has a wavelength of about 2500 mm or more and about 3000 mm or less.  
     
     
         4 . A method as defined in  claim 3 , wherein said waveform has a mean height of about 10 mm or more and about 400 mm or less.  
     
     
         5 . A method as defined in  claim 1 , wherein said waveform has a mean height of about 10 mm or more and about 400 mm or less.  
     
     
         6 . A method as defined in  claim 1 , wherein said desired shape memory is imparted on said weld wire at least partially prior to said weld wire being wound on said spool.  
     
     
         7 . A method as defined in  claim 1 , wherein said desired shape memory is at least partially retained on said weld wire after said weld wire is unwound from said spool.  
     
     
         8 . A method as defined in  claim 1 , wherein said desired shape memory is at least partially retained on said weld wire after said weld wire is unwound from said spool.  
     
     
         9 . A method as defined in  claim 1 , further comprising at least partially removing an initial shape memory on said weld wire resulting from said forming of said weld wire prior to imparting said desired shape memory on said weld wire.  
     
     
         10 . A packaged supply of large diameter weld wire, comprising: a spool or container; and a length of welding wire wound on or in said spool or container, said welding wire having a desired shape memory substantially lying in a single plane when said weld wire is removed from said spool or container, wherein said shape memory is generally a repeating sinusoidal waveform having a wavelength and a height for each waveform cycle.  
     
     
         11 . A packaged supply of large diameter weld wire as defined in  claim 10 , wherein said weld wire has a diameter of about 0.079 inches or more and about 0.190 inches or less.  
     
     
         12 . A weld wire for storage on or in a spool or container of weld wire, said wire comprising a desired shape memory comprising a substantially sinusoidal repeating waveform having a wavelength and a height for each waveform cycle, said shape memory substantially lying in a single plane when said weld wire is removed from said spool or container.  
     
     
         13 . A weld wire as defined in  claim 12 , wherein said weld wire has a diameter of about 0.079 inches or more and about 0.190 inches or less.  
     
     
         14 . A weld wire as defined in  claim 13 , wherein said waveform has a wavelength of about 2500 mm or more and about 3000 mm or less.  
     
     
         15 . A weld wire as defined in  claim 14 , wherein said waveform has a mean height of about 10 mm or more and about 350 mm or less.  
     
     
         16 . A weld wire as defined in  claim 13 , wherein said waveform has a mean height of about 10 mm or more and about 350 mm or less.  
     
     
         17 . A weld wire as defined in  claim 12 , wherein said waveform has a mean height of about 10 mm or more and about 350 mm or less.  
     
     
         18 . A weld wire as defined in  claim 12 , wherein said waveform has a wavelength of about 2500 mm or more and about 3000 mm or less.  
     
     
         19 . A weld wire as defined in  claim 12 , wherein said weld wire has a diameter of about 2 mm or more and about 4.0 mm or less.  
     
     
         20 . A weld wire as defined in  claim 19 , wherein said weld wire is a submerged arc welding (SAW) wire.  
     
     
         21 . A weld wire as defined in  claim 12 , wherein said weld wire is a solid wire comprising a solid electrode material.  
     
     
         22 . A weld wire as defined in  claim 12 , wherein said weld wire is a cored wire comprising a metallic outer sheath surrounding an inner core.  
     
     
         23 . A weld wire as defined in  claim 12 , wherein said weld wire has a diameter of about 0.070 inches or more.